BLACKBIRD INSTALLATION SUPPLEMENTBlackbird Installation Supplement for Ford 6.4 Liter Diesel -...

BLACKBIRD INSTALLATION

SUPPLEMENT

FOR 2008 FORD 6.4 LITER DIESEL

F-SERIES

Blackbird Installation Supplement for Ford 6.4 Liter Diesel - Version 10/9/08

Raven Technology, LLC ~ 14 Industrial Parkway, ME 04011 ~ 207-721-1044 ~ www.raventechpower.com ~ page 1

Parts

Blackbird Wiring Manual

Installation Supplement 6.4 liter Diesel

Owner’s Manual Includes Warrantee Registration

Generator Bracket With idlers and tensioner

Standoffs (2)

Fasteners (4) 5/8” 11 x 1¼” w/ flat washers

Upper brace block Mounts over OEM secondary alternator or bosses

(2) M10 x 100 mm w/ flat washers (dual alternator)

(2) M10 x 45mm w/ flat washers (single alternator)

(1) M10 x 30mm w/ flat washer

Engine bracket

Bracket spacers (2)

Spacer fasteners (3) M12 x 60mm bolt w/ flatwasher

Stator Standoff (1) M12 x 65mm stud

Crankshaft Pulley 8”

Fasteners (3) M10 x 45mm with flat washers

Pulley spacer

Fasteners (3) M10 x 60 socket head

Cooling Fan Spacer Male/female reverse thread

Generator Belt NAPA 25-060975 or equivalent

Generator mounting bolts (4) 3/8-16 x ¾” flat head socket

Generator Temporary Alignment Stud 3/8-16 x 1 ¼”

Generator Clutch 3” 6-groove electric

Clutch Key 3/16” x 1 ¾”

Clutch bolt (1) 7/16”-20 x 2 1/4” Grade w/ lock washer

Power post with battery post adapter

Fasteners (2) #14 x 2” self drilling

Oil fill relocator block Aluminum w/ gasket

Fasteners (4) M6 x 25 socket head

Drain hose extension assembly ½” x 2” hose and coupling

Air intake hose Blue silicon

Air conditioning extension tube

Fastener (1) M8 X 45mm bolt w/ flatwasher and nut

Seals O-ring and gasket

Sensor wire harness extension

Heater hose chafe guard 1¼ x 6” w/ tie-wrap

Fan plug support bracket Notched aluminum plate

Fasteners (2) 4”, (1) 8” tie-wrap

Electrical: Mechanical installers- forward these parts

to the electrical department

Clutch Harness Red/black with thermal fuse

243 Hz Command Module



General Instructions

This document supplements the Blackbird Wiring Manual with

information specific to the 2008 F-Series truck with the 6.4 liter

diesel engine. Contact Raven (207-721-1044) if more

documentation is needed.

This installation requires a minimum engine RPM of 1200 to deliver

the full 5kW output of the system. Beyond 1200 RPM generator

output will be unaffected by changes in engine speed. Arrangements

must be made for the engine to high idle when the generator is

engaged.

• All installation steps must be completed before operating the

system.

• Use Loctite 262 on all engine and bracket mounted bolts, except as noted.

• Refer to torque chart for torque specifications

• All hoses and wires moved or relocated during installation must be secured to prevent chafing

and exposure to hot surfaces. At no time should wiring be secured to fuel or exhaust system

components.

Care must be taken that any grounding straps, battery cables and battery feeds are reconnected in an

appropriate manner if moved during installation.

Preparing for Installation

Note: The heat exchanger module (radiator, intercooler, air conditioning, etc.) may

either be tilted ahead, or completely removed to access the fan shroud, fan, and

front of the engine. Take a moment to review the steps and locate the components

involved before deciding which you want to do.

1. Be careful of the corners of the hood-ouch!

2. Discharge air conditioning system

3. Disconnect all battery terminals and remove the passenger-side battery for relocation.

4. Drain the radiator

5. Disconnect the fuel cooler from the driver’s side of the radiator module and swing it aside. Do

not drain.

6. Remove the charge air cooler from the front of the radiator module.

7. Disconnect the power steering fluid cooler and swing it aside. Do not drain.

8. Disconnect the air conditioning hoses from the condenser

9. Remove the radiator support cross beam.

10. Remove the passenger’s side charge air cooler pipe

11. Remove two power steering reservoir bolts, pull the reservoir up and away from the fan shroud.

Do not drain.

12. Disconnect the upper radiator hose and expansion tank hose from the radiator.

13. Remove the four fan shroud assembly bolts from the radiator.

14. Disconnect the hoses from the transmission cooler at the two in-line couplings.

15. Disconnect the lower radiator hose and remove the radiator.



16. Unplug the fan harness from the fan.

17. Remove the two bolts connecting the upper and lower fan shroud, and remove the upper shroud.

18. Remove the fan (turn the nut to the right to loosen).

19. Remove the lower shroud and fan stator. Note that the fuel cooler circulating pump mounts to the

lower shroud with two bolts.

20. Remove and discard the two lower engine-to-stator standoff studs.

21. Remove the passenger-side battery tray/washer bottle assembly. Trim the tray parallel to the

washer bottle and reinstall the bottle using the upper OEM bolt. See Figure 4

22. Remove the air filter and intake hose assembly. There are three prongs on the bottom in tight

rubber grommets. These must be pulled free for removal.

23. Remove and discard the air filter housing mounting bracket.

24. Remove the upper air conditioning condenser tube and charging pipe at the in-line flange fitting.

Figure 5

25. Remove and set aside the passenger-side negative battery cable.

26. Mount the supplied power post on the body frame behind the passenger-side headlight. Figure 5.

Installing the Bracket (Figures 1, 2, & 3

27. Install supplied M12 x 65mm stud in the upper of two threaded holes in the driver-side engine

block.

28. Install the lower bracket plate using the supplied standoff and two spacers. Torque fasteners

29. Check that the front of the harmonic damper is clean and, using the supplied bolts, install the

Raven crankshaft pulley spacer on the damper, and the pulley on the spacer.

30. Dual alternator trucks: Remove two outboard bolts from the secondary (upper) alternator. Install

the supplied upper brace block on the alternator using the supplied M10 x 100mm bolts and

washers. Single alternator trucks: install the block on the threaded alternator bosses using the

M10 x 45mm bolts. Leave finger tight until generator bracket is torqued in place.

31. Install the generator bracket on the lower bracket with two 5/8 x 1¼ bolts and the generator

brace block with one M10 x 30mm. Note that single and dual alternator trucks use different bolt

holes in the bracket for the M10 bolt. Torque fastenings, alternator block last.

Mounting the Generator

32. Before mounting the Generator, bench-fit the clutch and key to the Generator shaft. Dress as

necessary for a slip fit.

33. Ensure that the Generator electrical junction box cover is securely in place. Insert the 3/8”

temporary alignment stud finger tight in one threaded hole of the Generator bearing plate (shaft

end.) Orient the electrical box at the 2 o’clock position, and lower the generator into the bracket

inserting the temporary alignment stud into one of the four countersunk fastener holes. Assure

that the large Generator alignment ring machined into the bearing plate is seated fully in the

bracket slot. Do not apply any undue force or pressure to the electrical junction box.

34. Secure the Generator to the bracket using the 4 flat head bolts provided. Torque the 4 bolts to 25

ft. lbs. Do not loctite these bolts!

35. Install the electric clutch on the generator shaft insuring that the key aligns with the shaft keyway

and the cutout in the outer hub. Do not Loctite this bolt.



36. Install the generator belt according to Figure 1

Re-assembly

37. Position the fan stator over the two upper mounting studs and note where trimming will be

necessary for belt and idler clearance. The lower mounting boss will be removed entirely. Trim

the stator as required. Figure 6

38. Position the lower fan shroud and reattach the fuel cooling pump.

39. Install the trimmed fan stator.

40. Install the supplied fan spacer and fan.

41. Bolt the upper fan shroud to the lower shroud.

42. Reconnect the power steering reservoir to the upper shroud.

43. Widen the fan harness hole in the upper shroud to allow the connector to pass through. Make a

hole in the shroud from the top for future access to the harness lock. Figure 7

44. Slide the supplied aluminum fan plug support bracket into the original grooves which held the

plug.

45. Attach the fan plug to the bracket by drilling through the holes in the bracket into the flanges on

the fan plug. Secure with two 4” tie wraps or pop rivets. Use the 8” wrap to secure plug assembly

to the shroud.

46. Reinstall the radiator, leaving the upper hoses off for the present. Reconnect the transmission

cooling lines.

47. Reconnect the fan shroud to the radiator.

48. Remount the power steering cooler on the radiator.

49. Reinstall the charge air cooler.

50. Remount the fuel cooler.

51. Install the charge air pipe.

52. Reinstall the radiator support cross beam.

53. Connect the upper radiator hoses.

54. Connect the OEM positive battery cable and its 4 smaller cables to the power post installed in

Step 26. Route the cables under the generator and between the inner fender and the support

beam. Take care that the cables are protected from sharp edges or abrasion. The cross-cable to

the driver-side battery can be unclipped and repositioned as necessary. Figure 5

55. Locate the heater hoses behind the air filter housing location. Tie the lower hose back against the

upper hose. Use supplied chafe guard as necessary. Figure 8

56. Carefully bend the transmission dipstick tube back about two inches to make room for the air

filter neck and to assist step 57.

57. Remove the engine oil fill housing and reposition it rearward using the supplied relocation

assembly, gasket, and bolts. Use OEM bolts to reinstall the oil fill housing. Figure 9

58. Extend and reconnect the oil fill drain hose using the supplied hose and coupling.

59. Install the supplied air conditioning extension tube in the condenser line previously

disconnected. The line connecting to the condenser must be bent to allow the upper end to

connect with the extension. Slight bending of the extension and related tubing may be required to

clear the generator and OEM components. Appropriate bending tools must be employed to

prevent damage to or kinking of the tubing. Figure 5

60. Reconnect the two condenser lines at the condenser.



61. Extend the air conditioning sensor wire harness to the sensor’s new location using the supplied

harness.

Wiring the generator junction box may be most easily done before final installation of the air filter

housing.

62. Modify the air filter housing by trimming the air intake duct according to Figure 10. This will

allow proper clearances for the air intake elbow and the engine air intake.

63. Set the housing in place behind the generator.

64. Install the supplied intake elbow between the air filter housing and the engine. Assure no contact

between the generator and the housing.

65. Refill radiator and top off the transmission fluid.

This completes the vehicle specific instructions. Refer to the Blackbird Wiring Manual

for wiring, run up, and troubleshooting instructions.

Figure 1

Upper Brace Block

(dual alternator shown)

Figure 2



Figure 3

Figure 4 Figure 5

Lower Bracket Spacers

Generator Bracket

Trim Line

Power Post



Figure 6

Figure 7

Figure 8

Figure 9

Figure 10



Battery Relocation: Optional Battery Relocation Kit – Parts

Procedure The OEM negative battery cable can be drawn back down to the vicinity of the starter and connected

to the relocated battery without cutting.

1. Mount the battery box adapter plate to the frame rail below the passenger’s door using the

supplied fasteners (Following Page).

2. Mount the Ford OEM battery box to the plate and connect the suspension cables.

3. Connect a battery cable to the positive starter stud and the OEM positive battery cable clamp.

Use heat shield to protect the cable from exhaust system heat.

Battery box (Obtain Locally) Ford OEM 10769B (Econoline Catalog)

Support tray (Obtain Locally) Ford OEM 10732 (Econoline Catalog)

Box cover (Obtain Locally) Ford OEM 10A687 (Econoline Catalog)

Fasteners (2) ¼-20 x ¾ truss head w/ flat washer and nut

Frame mounting plate 3/8” steel

Standoffs (2)1 1/2” diameter x 1 5/8”

(1) rectangular

Fasteners

Plate to frame (1) M10 x 25 flathead

(2) M10 x 80mm

(1) M10 x 35mm

(03) M10 lock washers

(3) M10 nuts

(3) M10 x 30mm fender washers

(3) M10 flat washers

Box to plate (2) M8 x 15mm bolts

(2) M8 flatwashers

(4) M10 x 25mmflange head bolts

Cable (Obtain Locally) 36” Red #2, terminal x 3/8” eye



FORD 6.4 L BATTERY BOX RELOCATION BRACKET

Use: Ford Econoline Support Box 10769B

Ford Econoline Battery Cover 10A687

Ford Econoline Support Tray 10732

The relocation plate is bolted to the frame rail under the passenger side door as shown in

the diagrams. The bolts use existing frame rail holes and the wheel strut brace. The Ford

battery box and support cables mount to the plate.

Battery

mounting plate

Frame Rail on

Passenger Side

Wheel

Strut

Bolts and standoffs

through frame

Plate Bolts to End of

Wheel Strut Bracket

BLACKBIRD INSTALLATION SUPPLEMENTBlackbird Installation Supplement for Ford 6.4 Liter Diesel -...

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